MECHANICAL PROPERTIES OF CONCRETE INCORPORATING SPENT

ABRASIVE WASTE

NUR BALQIS IDAYU BINTI MAHMAD RASEH

A project report submitted in partial fulfilment of the

requirements for the award of the degree of

Master of Engineering (Structure)

School of Civil Engineering

Faculty of Engineering

Universiti Teknologi Malaysia

JANUARY 2019

iii

DEDICATION

I dedicate this work to my family especially my mother and father.

I would like to thank Allah S.W.T for blessing me with excellent health and

ability during the process of completing my thesis.

iv

ACKNOWLEDGEMENT

I wish to express my special thanks to my supervisor, Dr Nor Hasanah binti

Abdul Shukor Lim who had taken a lot of efforts to meticulously go through my

thesis and came up with helpful suggestion. Without helping from her, I surely came

into deep problem in completing this thesis.

My gratitude is also extended to the “Structure and Materials Laboratory”

staff for their assistances in this research.

Finally, I would like to thanks to my friends, Muhammad Fakhrur Razi bin

Mohd Nordin, Siti Aisyah binti Fathol Karib and Nurizaty binti Zuhan for their

helped and support.

v

ABSTRACT

This research presents some results and discusses the possibility of using

spent abrasive waste in concrete. The key objective of this research was to determine

the characteristic of spent abrasive waste including the spent garnet and spent copper

slag, to investigate the appropriate amount of spent abrasive waste as substitution

substances for fine aggregates and cement in concrete and in addition to investigate

the mechanical properties of concrete incorporating spent abrasive waste. Various

tests were carried out to determine the characteristic of materials including strength

activity index, density, bulk density, sieve analysis, water absorption, ultrasonic

pulse velocity and wet sieve. For mechanical properties, compressive strength,

flexural strength and splitting tensile strength were tested. X-ray fluorescence was

used to study the chemical composition of the materials. Spent garnet replacement

level of 100% revealed the best performance regarding both water absorption of

concrete and mechanical properties. In addition, the use of 20% of spent copper slag

as cement replacement can produce higher compressive strength at the age of 28 days

by 14% compared with control specimens. The results revealed that spent garnet and

spent copper slag can be used as cement and fine aggregates replacement in concrete

production as the physical and chemical properties were satisfied by the standards.

vi

ABSTRAK

Kajian ini membentangkan beberapa hasil dan membincangkan kemungkinan

penggunaan sisa buangan kasar dalam konkrit. Objektif utama penyelidikan ini

adalah untuk menentukan sifat sisa buangan kasar termasuk sisa garnet dan sisa

tembaga sanga, untuk mengkaji jumlah sisa buangan kasar yang sesuai sebagai bahan

penganti untuk agregat halus dan simen dalam konkrit dan tambahan pula, untuk

menyiasat kekuatan mekanik konkrit yang menggabungkan sisa buangan kasar.

Pelbagai ujian telah dijalankan untuk menentukan ciri-ciri bahan termasuk indek

aktiviti kekuatan, ketumpatan, ketumpatan pukal, analisis ayak, penyerapan air,

halaju denyutan ultrasonic dan ayak basah. Bagi sifat mekanikal, kekuatan

mampatan, kekuatan lenturan dan kekuatan tegangan telah diuji. ‘X-fluorescence’

digunakan untuk mengkaji komposisi bahan kimia. Tahap penggantian sisa garnet

sebanyak 100% menunjukkan prestasi terbaik mengenai penyerapan air konkrit dan

sifat mekanikal. Di samping itu, penggunaan 20% sisa tembaga sanga sebagai

pengganti simen boleh menghasilkan kekuatan mampatan yang lebih tinggi pada usia

28 hari sebanyak 14% berbanding dengan spesimen kawalan. Keputusan

menunjukkan bahawa sisa garnet dan sisa tembaga sanga boleh digunakan sebagai

penggantian agregat halus dan simen dalam pengeluaran konkrit kerana sifat fizikal

dan kimia dipenuhi oleh piawaian.

vii

TABLE OF CONTENTS

TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF ABBREVIATIONS xiii

LIST OF SYMBOLS xiv

LIST OF APPENDICES xv

CHAPTER 1 INTRODUCTION 1

1.1 Background of Study 1

1.2 Problem Statement 2

1.3 Aim and Objectives 3

1.4 Scope of Study 4

CHAPTER 2 LITERATURE REVIEW 7

2.1 Introduction 7

2.2 Composition of Concrete 8

2.2.1 Ordinary Portland cement (OPC) 8

2.2.2 Aggregate 8

2.2.2.1 Coarse Aggregates 8

2.2.2.2 Fine Aggregates 9

2.3 Utilization of Waste Materials as Sand Replacement in Concrete

Production 9

2.4 Utilization of Pozzolanic Materials in Concrete Production 11

viii

2.5 Spent Abrasive Waste 12

2.5.1 Spent Garnet as Recycled Aggregate 13

2.5.1.1 Physical Properties of Spent Garnet 14

2.5.1.2 Percentage Replacement of Spent Garnet 15

2.5.2 Copper Slag as Blended cement 15

2.5.2.1 Chemical Composition of Copper Slag 16

2.5.2.2 Physical Properties of Copper Slag 17

2.6 Mechanical Properties 18

2.6.1 Effect of Spent Garnet on Mechanical Properties 18

2.6.2 Effect of Copper Slag on Mechanical Properties 18

2.7 Summary of Research Gap 20

CHAPTER 3 MATERIALS AND METHODS 21

3.1 Introduction 21

3.2 Research Design 23

3.3 Materials 24

3.3.1 Spent Garnet 24

3.3.2 Spent Copper Slag 24

3.4 Mix Proportion 25

3.5 Specimens Preparation 26

3.6 Hardened Concrete Test 28

3.6.1 Compressive Strength Test 28

3.6.2 Flexural Strength Test 29

3.6.3 Splitting Tensile Strength Test 31

3.6.4 Ultrasonic Pulse Velocity (UPV) 32

3.7 Chemical properties 33

3.7.1 X-ray Fluorescence (XRF) 33

3.8 Physical properties 34

3.8.1 Strength Activity Index 34

3.8.2 Density 34

3.8.3 Sieve Analysis 35

3.8.4 Water Absorption 36

ix

3.8.5 Bulk Density 36

3.8.6 Wet sieve 37

CHAPTER 4 RESULT AND DISCUSSIONS 39

4.1 Introduction 39

4.2 Characteristics of Binder 39

4.2.1 Physical Properties 40

4.2.2 Chemical Properties 41

4.3 Characteristic of Fine Aggregates 42

4.3.1 Physical Properties 42

4.3.2 Grading of Fine Aggregates 43

4.4 Mix Design 44

4.4.1 Percentage of Spent Garnet 44

4.4.2 Percentage of Spent Copper Slag 45

4.5 Mechanical Properties 45

4.5.1 Effect of Spent Garnet in Compressive Strength 45

4.5.2 Density 46

4.5.3 Compressive Strength 48

4.5.4 Splitting Tensile Strength 50

4.5.5 Flexural Strength 52

4.5.6 Ultrasonic Pulse Velocity (UPV) 54

4.5.7 Water Absorption 57

4.6 Summary 58

CHAPTER 5 CONCLUSIONS AND RECOMMENDATIONS 61

5.1 Conclusions 61

5.2 Recommendations 62

REFERENCES 63

x

LIST OF TABLES

TABLE NO. TITLE PAGE

Table 2.1 Physical properties of spent garnet and river sand (Muttashar et al.,

2018) 14

Table 2.2 Chemical composition of copper slag from previous study 17

Table 3.1 The designs mix proportion for trial mix 25

Table 3.2 The designs mix proportion 26

Table 3.3 Total number of samples required for trial test 27

Table 3.4 Total number of samples required for compressive strength 27

Table 3.5 Total number of samples required for flexural strength 27

Table 3.6 Total number of samples required for splitting tensile strength test 28

Table 4.1 Physical properties of OPC and spent copper slag 40

Table 4.2 Chemical composition of OPC and spent copper slag 42

Table 4.3 Physical properties of fine aggregates and spent garnet 43

Table 4.4 Effect of Spent Garnet in Compressive Strength 46

Table 4.5 Effect of spent copper slag on compressive strength of concrete 49

Table 4.6 Effect of spent copper slag on splitting tensile strength of concrete 51

Table 4.7 Effect of spent copper slag on flexural strength of concrete 53

Table 4.8 Concrete quality (Neville, 2011) 55

Table 4.9 Water absorption at age 28 days 57

xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE

Figure 2.1 Spent garnet used as fine aggregate (Muttashar et al., 2018) 14

Figure 2.2 Copper slag (Al-jabri et al., 2009) 16

Figure 2.3 Compressive strength of self-compacting geopolymer concrete

(Muttashar et al., 2018) 18

Figure 2.4 Average 7, 28 and 90 days compressive strength of different concrete

mixes (Singh et al, 2016) 19

Figure 3.1 Scope of Work 22

Figure 3.2 Experimental programme of the research work 23

Figure 3.3 Spent Garnet 24

Figure 3.4 Spent copper slag 25

Figure 3.5 Compressive strength test 29

Figure 3.6 Flexural strength test 30

Figure 3.7 Splitting tensile strength test 32

Figure 3.8 Ultrasonic pulse velocity test equipment 33

Figure 3.9 Density of hardened concrete 35

Figure 3.10 Wet sieve 37

Figure 4.1 OPC and spent copper slag 40

Figure 4.2 Strength activity index of spent copper slag at age 7 and 28 days 41

Figure 4.3 Grading of fine aggregates and spent garnet 44

Figure 4.4 Compressive strength of Spent Garnet 46

Figure 4.5 The density of concrete with spent garnet 47

Figure 4.6 The density of concrete with spent copper slag 48

Figure 4.7 Effect of spent copper slag on compressive strength of concrete 49

Figure 4.8 Relationship between compressive strength and density of concrete 50

Figure 4.9 Effect of spent copper slag on splitting tensile strength of concrete 51

Figure 4.10 Relationship between compressive strength and splitting tensile

strength of concrete 52

xii

Figure 4.11 Effect of spent copper slag on flexural strength of concrete 53

Figure 4.12 Relationship between compressive strength and flexural strength of

concrete 54

Figure 4.13 Effect of concrete a)cube b)beam c)cylinder on UPV 56

Figure 4.14 Relationship between UPV and compressive strength of concrete 56

Figure 4.15 Water absorption at age 28 days 58

xiii

LIST OF ABBREVIATIONS

OPC - Ordinary Portland cement

CO2 - Carbon dioxide

SCGC - Self-compacting geopolymer concrete

UPV - Ultrasonic pulse velocity

XRF - X-ray Fluorescence

SG - Spent garnet

CS - Copper slag

S - Sand

R2 - Coefficient of determination

Fe2O3 - Ferum Oxide

SiO2 - Silica Oxide

Al2O3 - Aluminium Oxide

CaO - Calcium Oxide

MgO - Magnesium

MnO - Manganese

TiO2 - Titanium Dioxide

K2O - Potassium Oxide

P2O5 - Phosphorus Pentoxide

ZnO - Zinc Oxide

Cr2O3 - Chromium(III) Oxide

LOI - Loss of Ignition

SO3 - Sulphur

Cl - Chloride

CuO - Copper Oxide

xiv

LIST OF SYMBOLS

P - Ultimate compressive load of concrete

A - Surface area in contact with the plates

R - Modulus of rupture

L - Span length

b - Average width of specimen

d - Average depth of specimen

T - Splitting tensile strength

V - Pulse velocity

T - Transit time

D - Density (unit weight) of concrete

Wc - Mass of the concrete

Vc - Volume of the measure

Wa - Percentage of water absorption

Ww - Weight of wet specimen

Wd - Weight of dry sample

M - Bulk density of the aggregate

G - mass of the aggregate plus the measure

V - volume of the measure

-

xv

LIST OF APPENDICES

APPENDIX TITLE PAGE

Appendix A Mix Design 69

Appendix B Gantt Chart 71

1

CHAPTER 1

INTRODUCTION

1.1 Background of Study

Concrete is a composite material which is made of filler and a binder that is

widely used in construction. Concrete mix generally consists of cement, aggregates

(sand and granite), and water mixed together. Materials such as sand and gravel form

the most part of the aggregates. According to Omar et al., (2016), about 70-80% of

aggregates represent in concrete components. Continuous extraction of aggregates

has caused resources depletion at an increasing rate. Reported by Muttashar et al.,

(2018), the growing use of sand from the river for some purpose of construction,

which led to the use of more rivers’ bed and disturbed the ecosystem. Therefore,

there is a need in finding new material to solve this problem.

A study by Abdel-Hay, (2015), a lot of wastes are produced every day from

construction and demolition such as concrete, bricks, ceramics, rubber and glass

(Verian et al., 2018). Some wastes are being handled properly but some are not.

These wastes would be beneficial if they are processed into something that could be

used in construction. According to Muttashar et al., (2018), waste materials such as

spent garnet can develop sustainable product and at the same time will reduce the

cost which proves to be most economical.

Meanwhile, the production of one tonne of Ordinary Portland Cement (OPC)

can generate one tonne of carbon dioxide (CO2). Such high rates of emission of CO2

significantly contribute to global warming and climate change (Ariffin and Hussin,

2015). Due to the increasing cost of material, replacement of OPC with waste

material such as copper slag which can offer the opportunity to get efficient

construction materials via their appropriate recycling method. Using it as cement is if

permitted, it will be more convenient, economical in the construction field.

2

According to Zhang et al., (2018), the possible way to use copper slag is to

use it in concrete production. Due to the increasing of large required area for disposal

of this waste, there are many ways to use it such as in the construction of pavement.

Al-Jabri et al., (2011) reported that copper slag is materials that qualify to be used in

concrete production as replacement of OPC. According to Uysal et al., (2011), waste

material can decrease the permeability of concrete. Replacement of cement is not

only helps in their strength and durability. It also helps in reducing the cost of cement

and also has numerous benefit (McGinnis et al., 2017). Therefore, exploring this

abrasive waste as cement and fine aggregates replacement in concrete would create

an advanced waste material. This will also help improve the performance of concrete

and reduce the landfill problem of waste disposal.

1.2 Problem Statement

Over the last decade, the demand for natural resources has increased so far

that it is now considered a serious threat to our economic and social balance. The

process of producing cement not only depleted the natural resources such as

limestone and clay but can cause serious impact on the environment. In addition, the

continuous extraction of natural aggregate can causes soil erosion and destruction of

the ecosystem (Kim et al., 2016).

The production of cement involves large quantities of raw materials, energy,

and heat. Besides, the higher amount of OPC used in concrete production can be

affected by the presence of pollutions in the environment such as CO2, sulphur

oxides and suspended particulate matter (Rambabu, 2017). There are a ways to limit

the consumption of OPC, one of it is employing of copper slag in concrete

production. Some research revealed the effects of concrete content OPC suffered the

highest rise in permeability and porosity (Pavía and Condren, 2008). In order to find

a more durable and dense concrete in this environment, incorporating pozzolanic

material such as spent copper slag in concrete production is needed. In addition,

nearly 68.7 million tonnes of copper slag is generated per year and will cause risks of

pollution. This is because of no proper way to treating the copper slag waste and the

3

way to dispose the copper slag in a sustainable way is employing in concrete

production (Zhang et al., 2018).

Furthermore, there is an increasing demand to find another material as

alternative materials to be used as aggregate in concrete. A recent assessment of the

Malaysian shipyard industry revealed that the country import approximately 2000

million tonnes of spent garnets in the year 2013 alone and the quantities are widely

discharged as waste (Muttashar et al., 2018). Spent garnet is considered as one of the

serious problems of waste generation by the industries. Besides, spent garnet can be

used for production of new concrete by replacing natural fine aggregates such as

sand at different levels of construction.

The sustainable development for construction involves use of non-

conventional and innovative materials, and reuse waste material to compensate for

the lack of natural resources and to find an alternative way to preserve environment

(Ambily et al., 2015). Additionally, using of waste material had a good influence on

the performance of concrete. Use of spent garnet and spent copper slag can reduce

manufacturing waste which usually ends at the landfills. On the other hand, it can

save the use of natural resources.

Therefore, in order to evaluate the potential use of spent garnet and spent

copper slag from shipyard industries, a comprehensive study on the fundamental

characteristic of materials and mechanical properties of concrete are necessary.

1.3 Aim and Objectives

The aim for this research is to study the effect of spent garnet and spent

copper slag on mechanical properties of concrete. The specific objectives are as

follows:

1. To determine the characteristic of spent garnet and spent copper slag as fine

aggregates and cement replacement in concrete.

4

2. To investigate the appropriate amount of spent garnet and spent copper slag

as substitution substances for cement and fine aggregates in concrete.

3. To investigate hardened properties of concrete incorporating spent garnet and

spent copper slag.

1.4 Scope of Study

The scope of the study will focus on the use of spent garnet and spent copper

slag as the replacement of fine aggregates and cement in concrete production. The

spent abrasive wastes are acquired from Malaysia Marine and Heavy Engineering

(MMHE).

The first stage deals with characterization of materials and testing of the

properties of spent garnet and spent copper slag. These comprise; strength activity

index, density, bulk density, sieve analysis, water absorption, specific gravity and

wet sieve. It also deals with the determination of the chemical compositions of spent

copper slag by X-ray fluorescence (XRF).

The second stage deals with mix design and proportioning of the materials for

concrete. The percentages of spent garnet replacement into the concrete mixer are

0% (as control), 25%, 50%, 75% and 100%. Trial test will determine the appropriate

amount of spent garnet and it will be used as benchmark. The mechanical properties

for trial test are to be conducted at the age of 7, 14 and 28 days. The mineral

admixture used in this study is spent copper slag which replaced the amount of OPC.

The percentage of spent copper slag will be used as cement replacement are 10%,

20% and 30%.

The third stage deals with the investigation of hardened state properties. For

hardened state properties of concrete, the mechanical properties including

compressive strength, splitting tensile strength and flexural strength are to be

conducted at the age of 7, 14 and 28 days after curing process. In addition to

5

compressive, tensile and flexural strength tests, density, ultrasonic pulse velocity and

water absorption was also conducted to examine the relationship. Concrete were

design according to Department of Environment (DoE) method with 50 MPa at 28

days. The procedure will be used based on ASTM Standard and BS Standard.

63

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